Palletless packaging system

ABSTRACT

A connector for holding the modules of a palletless packaging system in assembled relation, the module of the palletless packaging system having a pair of opposed end walls and a pair of opposed, substantially parallel brace members extending between the pair of opposed end walls. The connector comprises a lower channel, an upper channel, and an end portion. The lower channel is dimensioned to straddle the top edge of and connect to the end wall. The upper channel extends along some portion of the connector and is dimensioned to receive the bottom edge of an end wall when one palletless packaging module is stacked upon another. The end portion of the connector is positioned to connect with a brace member.

FIELD OF THE INVENTION

The present invention relates generally to packaging, storage, and transport systems for wide-web roll products, and, more particularly to a packaging system that eliminates the requirement for a pallet.

BACKGROUND OF THE INVENTION

Conventional pallet systems have been known for decades and have been widely used for the storage and transport of all types of materials. Pallets have been economically formed as multi-level wooden platforms having spacers between the levels for the insertion of forklift tines for pickup and movement of the pallet, as well as to keep the contents of the pallet out of direct contact with the floor. These conventional wooden pallets, however, are not without their attendant problems. For instance, a significant amount of wood is required to construct these pallets, which means that they are quite heavy and bulky. Bulk and weight equate to higher storage and transportation costs. Additionally, wood becomes contaminated quite easily and, one contaminated, is nearly impossible to clean. This is a significant problem for manufacturing operations where “clean room” environments are mandated by the types of materials being processed.

In more recent years, these pallets have been formed of lightweight, rigid metal or hard plastic. While these material constructions have addressed somewhat the cleanliness concerns of wooden pallets, they are still bulky and suitable only for storing and transporting materials that can be stacked on the relatively flat bed of the pallet. That is, they are not suitable for the storage and transport of large rolls of material in which the axis of the roll is parallel to the surface of the pallet.

For the storage and transport of large rolls of web material, however, vertical supports or end walls have typically been permanently affixed to the bases of the pallets. To support large webs, however, the pallet constructions are again heavy and bulky, defeating in part the advances that have been made in lighter weight metal and plastic pallet constructions. This, of course, again leads to high storage and transportation costs.

One solution to the problem of large rolls has been the development of “palletless” packaging systems which are substantially lighter, thus reducing the costs of transportation. In a palletless system, the cores of the rolls are received and supported between large end walls having an elongated vertically extending opening therein, without a floor therebeneath. To stack the packaged rolls, the end walls for one roll are stacked on the end walls of the roll beneath. These known palletless systems, however, have proven less than satisfactory. Specifically, the vertical plates or end walls which support the large rolls of web material must be thick, bulky, and heavy. Further, stabilizers, large feet for the plates, and the like, offset some of the costs savings that are obtained from eliminating the pallet and support designs for wide web roll storage and transport.

SUMMARY OF THE INVENTION

The present invention is directed to a connector for a palletless packaging system and a palletless packaging system incorporating the connector that solves the problems associated with the prior art “palletless” packaging systems.

One aspect of the present invention is directed to improving this lightweight palletless packaging system. The palletless system includes modules formed by a pair of opposed end walls, each end wall having top and bottom edges that are similarly dimensioned. In one embodiment, a vertically elongated opening, or slot, is formed in each end wall, extending from the top edge downward, terminating approximately centrally of the end wall at a specified distance above the bottom edge of the end wall. The base of the opening provides the load bearing surface for the core or hollow tube of a supported roll of wide-web material. Alternatively, to support the core or hollow tube, a hole may be formed through each end wall, the diameter of the hole generally conforming to the diameter of the core or hollow tube of the supported roll.

A pair of spaced-apart, substantially parallel brace members are provided to extend between, be received in, and interconnect the top portions of the opposed end walls. Lastly, a plurality of connectors is provided to align and maintain the end walls of adjacent modules in alignment and to hold each of the braces in assembled relation with the tops of the opposed end walls. To further facilitate moving and stacking assembled systems upon one another, a conventional band or strap may be wrapped around the lower periphery of the assembled packaging system to ensure that the end walls remain vertical during movement.

Another aspect of the present invention is directed to a lightweight connector for a palletless packaging module of the type described. Unlike the end wall constructions of the prior art, the end walls that are used in conjunction with the connector described herein are very simple, generally planar. The term “module” is used herein to describe one roll with its supporting end walls, braces, and connectors.

The connector is preferably a molded polymeric body having a lower channel portion, an upper channel portion parallel to the lower channel portion, and an end flange portion on at least one end. The lower channel portion is generally U-shaped and is dimensioned to straddle a portion of the top edge of one of the end walls of the packaging system. As such, the lower channel comprises a pair of spaced-apart parallel flanges, with the distance between the flanges generally corresponding to, or being slightly greater than, the thickness of the end wall received therein. The lower channel portion will also include at least one opening for securing the lower channel of the connector with the adjacent end wall with some type of fastener.

The upper channel of the connector corresponds in length to the lower channel and is dimensioned to receive a portion of the bottom edge of a side wall of another palletless packaging module constructed and stacked on the first module in accordance with the present invention. The upper channel is generally V-shaped with opposed wall portions, each of the wall portions extending upwardly and outwardly. A horizontal lip, or flange, extends outwardly from the top edge of each opposed wall portion so that the bottom edge of the end wall of another module to facilitate guiding the wall of the upper module into a proper stacking arrangement.

The end flange portion of the connector is formed at one end of the connector to connect the end wall and the adjacent brace member. Accordingly, the end flange portion also includes at least one aperture that is positioned and dimensioned for insertion of a fastener.

These and other aspects of the present invention will become apparent to those skilled in the art after a reading of the following description of the preferred embodiments when considered in conjunction with the drawings. It should be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the palletless packaging system of the present invention;

FIG. 2 is an environmental view of the connector of FIG. 1 as installed on a palletless packaging system;

FIG. 3 is a bottom perspective view of the connector of FIG. 1;

FIG. 4 is a end perspective view of the connector of FIG. 1;

FIG. 5 is an environmental view of an alternative embodiment of the connector and an alternative embodiment of the end wall of the palletless packaging system of the present invention;

FIG. 6 is an exploded perspective view of the palletless packaging system of the present invention; and

FIG. 7 illustrates the stacking arrangement for the palletless packaging system of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

As shown in FIG. 1, one aspect of the present invention is directed to a palletless packaging system, one module of which is shown generally as 100, which is intended for the storage and transport of wide-web roll products 200.

In particular, each module 100 of the palletless packaging system of the present invention comprises a pair of opposed end walls 120, a plurality of horizontal brace members 140, and a plurality of connectors 160. Each of the opposed end walls 120 is preferably a simple rectangular polymeric plate having a top edge 121, a bottom edge 123, and a vertically elongated opening, or slot, 125 formed extending from the top edge 121 to a point 124 spaced from the bottom edge 123 of each end wall 120. Alternatively, and as shown in FIG. 5, a hole 525 may be formed through each end wall, the diameter of the hole generally conforming to the diameter of the core or hollow tube of the supported roll. The opposed end walls 120, 520 provide the primary supporting structure for the hollow core or tube 220 of the wide-web rolls 200. While there are numerous suitable materials for constructing the ends walls 120, 520, they are desirably formed from a molded or extruded rigid material such as high density polyethylene, high impact polystyrene, or ABS plastic.

As shown in FIG. 1, a pair of substantially parallel, opposed horizontal brace members 140 extend between and interconnect the opposed side walls 120. Notches 126, formed in the top edges of the opposed end walls, are dimensioned to receive the brace members 140. Notches 127 are provided in the bottom edge for reasons to be explained hereinbelow. The horizontal brace members provide stability to, and maintain a fixed distance between, the opposed end walls 120. The brace members may also be formed of a molded or extruded plastic, or may be formed of wood, such as conventional lumber, or other suitable materials.

Some type of interconnecting device must be provided to both align adjacent end walls of an upper and lower module and to secure the brace members to the corresponding end wall. The interconnecting device may be a single connector that accomplishes both purposes, or it may be two components, one aligning the end walls and the other securing the brace member. The preferred connector 160 of the present invention maintains the end walls in lateral alignment and holds each of the horizontal brace members 140 in assembled relation with the top edges 121 of the opposed side walls 120, 520. Referring more specifically to FIGS. 2 through 4, the construction of the connector 160 can be seen in greater detail. As best seen in the environmental view of FIG. 2, each connector 160 comprises a lower channel 162, an upper channel 164, and an end wall portion 166 on at least one end. In a preferred embodiment, the connector 160 is integrally formed with upper and lower channels; however, it would be possible to separate these functions if the two components were secured together.

The lower channel 162 is generally C-shaped or U-shaped with substantially parallel side walls 162 a, 162 b. A planar flange 165 extends therebetween and connects the side walls 162 a and 162 b. The lower channel is dimensioned so that the distance between the opposed side walls 162 a, 162 b is substantially equal or slightly greater than the thickness ‘t’ of an end wall 120, thus ensuring a close fit. The lower channel 162 further includes at least one slot 163 formed therealong the bottom edge of at least one of the opposed side walls 162 a, 162 b, wherein a guide or fastener 131 can be inserted for fastening the connector 160 to the side wall 120. Alternatively, the slot 131 could also be formed as an aperture formed therethrough one or both side walls 162 a, 162 b.

The end connector portion 166 of the connector 160 comprises a pair of coplanar flanges 166 a, 166 b; however, the end connector portion 166 may be formed as a single flange. The coplanar flanges 166 a, 166 b are substantially perpendicular to the longitudinal axis of flange 165. As best seen in FIG. 2, the coplanar flanges 166 a, 166 b of the connector portion 166 are situated to align with and abut the inner planar faces 140 a of the brace members 140. One or more slots or apertures 167 are formed therethrough at least one of the coplanar flanges 166 a, 166 b to connect at least one of the flanges 166 a, 166 b to the brace member 140. One or more fasteners 169 are inserted through apertures 167 to connect the connector 160 to the brace member 140, holding the brace member 140 in a fixed, assembled relation.

The upper channel 164 of the connector 160, which is an important aspect of the present invention, comprises opposed walls 164 a, 164 b that are interconnected by the flange 165. The spaced-apart side walls 164 a, 164 b each extend upwardly and outwardly from the flange 165. As will be better understood from the description that follows, the angled walls 164 a, 164 b facilitate the subsequent stacking of similarly constructed and assembled palletless packaging modules 100 upon one another. While not critical to the invention, it has been found than when at least one side wall 164 a, 164 b is angled at between about 30 degrees and 45 degrees from vertical, the stacking and movement of assembled packaging modules 100 is more easily accomplished. A lip, or flange 164 c, 164 d extends horizontally outward from the top edge of each wall 164 a, 164 b. A series of integrally formed reinforcing ribs 164 e extend between and interconnect with walls 162 a, 162 b, 164 a, 164 b, and lips 164 c, 164 d to provide a sufficiently rigid construction that will withstand the static and dynamic forces of packaging, stacking, and transport.

Turning now to FIG. 5, an alternative construction of the connector 560 is shown. In this embodiment, a single connector 560 extends continuously across the entire length of the end wall 520 between braces 140. As described above, end wall 520 is an alternative embodiment of an end wall construction. The connector 560 extends between and connects the two horizontal brace members 140. Constructed in this fashion, the flange 565 provides a substantially greater load bearing surface contact area for subsequently stacked modules. The lower channel 562, opposed end connector portions 566, upper channel 564, and associated reinforcing structure are otherwise formed in the same manner as the previously described connector 160.

Referring to FIG. 6, the method of assembling the modules 100 of the palletless packaging system will be described. The wide-web roll 200 that is ready to be packaged is first lifted or suspended, as by a forklift tine inserted through the hollow core 220 of the roll 200. The opposed end walls 120 are next positioned adjacent the ends of the roll 200 so that the outwardly extending core 220 of the roll 200 is supported within the vertically elongated opening 125 of each end wall 120. With the roll 200 still independently supported, the horizontal brace members 140 are interconnected between the end walls 120 such that the opposite ends of the brace members 140 are inserted into the slots 126 formed in the top edge 121 of the end walls 120. Connectors 160 are next seated astride the opposed top edges 121 of each end wall 120 so that the end connector portions 166 of each connector 160 abut the inner face 140 a of each horizontal brace member 140 (see FIG. 2). Fasteners 131, 132 are next inserted through the slots or apertures 163, 167 of each connector to secure the connectors of the module 100 in rigid assembled relation. To facilitate movement and storage, a band 260 (best seen in FIG. 1) is wrapped around the lower periphery of the system 100 to maintain the end walls substantially parallel and vertical during subsequent movement. Once assembled, the module 100, with one large wide-web roll packaged therein, is as shown in FIG. 1.

Turning lastly to FIG. 7, other novel aspects of the connectors 160, 560 and system 100 are best seen. As subsequent palletless systems 100 are assembled and prepared for storage or transport, the design of the connector 160, 560 facilitates quick and easy stacking of systems 100. With one module supported on a substantially level floor, a second module 100 may be stacked by lifting the second module via the hollow core 220 of the roll 200. As the roll is lifted, the horizontal brace members 140 of the second module will contain the roll 200 in the vertically elongated opening 125 of each end wall 120, and prevent the module from turning during movement. To laterally align the end walls 120 (or alternatively end walls 520) of each module, notches 127 in the bottom edges 123 of the second module are aligned and seated over the brace members 140 of the first module. Once in place, the second module cannot slide laterally. The angled walls 164 a, 164 b of the upper channel 164 of the first module allow an operator to easily align the bottom edges of the end walls 120 so that when lowered, even if not precisely aligned, the angled walls will urge the bottom edge of the end wall 120 of the second module downward against the flange 165. Flange 165 of each connector 160 then acts as the load bearing surface for the end walls 120 of the second module. Additionally, walls 164 a, 164 b are so angled that the end walls 120 of the second stacked module cannot inadvertently slide out of the connectors 160. Also, as previously described, the palletless packaging system may also comprise a band or strap 260 that wraps around all or a substantial portion of at least the lowermost module 100 to maintain the bottoms of the ends walls 120 is parallel relation.

Although the present invention has been described with preferred embodiments, it is to be understood that modifications and variations may be utilized without departing from the spirit and scope of the invention, as those skilled in the art will readily understand. Such modifications and variations are considered to be within the purview and scope of the appended claims and their equivalents. 

1. A stackable palletless packaging system for rolls of wide-web material wound about a core, the system comprising: (a) at least two modules, each module comprising a pair of opposed substantially planar end walls, each end wall having a top and bottom edge, a thickness, and a vertically elongated opening extending from a central portion of the top edge to a point spaced from the bottom edge of the end wall, the vertically elongated opening being so dimensioned as to receive the core of a roll of web material; (b) a plurality of spaced-apart brace members, each brace member extending between and interconnecting opposed end walls to maintain a fixed distance between the opposed end walls and to prevent lateral movement of the end walls of one module relative to the end walls of the module thereabove; and (c) at least one connector mounted on each end wall that maintains the end walls of one module in alignment with the end walls of the module thereabove and maintains the brace members in fixed relationship with the end walls.
 2. The stackable palletless packaging system of claim 1 wherein the top and bottom edges of the opposed end walls are similarly dimensioned.
 3. The stackable palletless packaging system of claim 1 wherein each end wall further includes a pair of spaced-apart slots formed in the top edge, each of the slots dimensioned for receiving a brace member.
 4. The stackable palletless packaging system of claim 1 wherein the connector comprises: (a) a lower channel dimensioned to straddle the top edge of and connect to one of the end walls; (b) an upper channel extending along some portion of the connector and dimensioned to receive the bottom edge of the end wall of the module thereabove; and (c) an end portion being releasably securable to one of the brace members.
 5. The stackable palletless packaging system of claim 3 wherein the lower channel of the connector is U-shaped and comprises: (a) a pair of spaced-apart, substantially vertical wall portions; and (b) a horizontal flange interconnecting the pair of vertical walls, wherein the distance between the vertical wall portions approximates the thickness of the end wall being straddled.
 6. The stackable palletless packaging system of claim 5 wherein the lower channel further includes at least one opening formed in at least one of the vertical walls thereof, wherein the at least one vertical wall is releasably fastenable to the end wall.
 7. The stackable palletless packaging system of claim 4 wherein the upper channel of the connector is V-shaped and comprises: (a) a pair of spaced-apart walls; and (b) a horizontal flange interconnecting the pair of spaced-apart walls, each of the walls extending upwardly and outwardly from the horizontal flange, wherein the width of the flange approximates the thickness of the end wall received therein.
 8. The stackable palletless packaging system of claim 7 further including reinforcing ribs integrally formed with and connecting the spaced-apart walls of the upper channel with the adjacent walls of the lower channel.
 9. The stackable palletless packaging system of claim 4 wherein the end portion of the connector comprises: (a) at least one flange extending perpendicularly to the longitudinal axis of the connector, and (b) at least one aperture formed therethrough the at least one flange, wherein the at least one flange is releasably fastenable to an adjacent one of the brace members.
 10. A stackable palletless packaging system for rolls of wide-web material wound about a core, the system comprising: (a) at least two modules, each module comprising a pair of opposed substantially planar end walls, each end wall having a top and bottom edge and a thickness, a centrally positioned hole formed therethrough the thickness, the hole being so dimensioned as to receive the core of a roll of web material; (b) a plurality of spaced-apart brace members, each brace member extending between and interconnecting the opposed end walls to maintain a fixed distance between the opposed end walls and to prevent lateral movement of the end walls of one module relative to the end walls of the module thereabove; and (c) at least one connector mounted on each end wall that maintains the end walls of one module in alignment with the end walls of the module thereabove and maintains the brace members in fixed relationship with the end walls.
 11. The stackable palletless packaging system of claim 10 wherein the top and bottom edges of the opposed end walls are similarly dimensioned.
 12. The stackable palletless packaging system of claim 10 wherein each end wall further includes a pair of spaced-apart slots formed in the top edge, each of the slots dimensioned for receiving a brace member.
 13. The stackable palletless packaging system of claim 10 wherein the connector comprises: (a) a lower channel dimensioned to straddle the top edge of and connect to the end wall; (b) an upper channel extending along some portion of the connector and dimensioned to receive the bottom edge of the end wall of the module thereabove; and (c) an end portion being releasably securable to one of the brace members.
 14. The stackable palletless packaging system of claim 13 wherein the lower channel of the connector is U-shaped and comprises: (a) a pair of spaced-apart, substantially vertical wall portions; and (b) a horizontal flange interconnecting the pair of vertical walls, wherein the distance between the vertical wall portions approximates the thickness of the end wall being straddled.
 15. The stackable palletless packaging system of claim 13 wherein the lower channel further includes at least one opening formed in at least one of the vertical walls thereof, wherein the at least one vertical wall is releasably fastenable to the end wall.
 16. The stackable palletless packaging system of claim 13 wherein the upper channel of the connector is V-shaped and comprises: (a) a pair of spaced-apart walls; and (b) a horizontal flange interconnecting the pair of spaced-apart walls, each of the walls extending upwardly and outwardly from the horizontal flange, wherein the width of the flange approximates the thickness of the end wall received therein.
 17. The stackable palletless packaging system of claim 16 further including reinforcing ribs integrally formed with and connecting the spaced-apart walls of the upper channel with the adjacent walls of the lower channel.
 18. The stackable palletless packaging system of claim 13 wherein the end portion of the connector comprises: (a) at least one flange extending perpendicularly to the longitudinal axis of the connector, and (b) at least one aperture formed therethrough the at least one flange, wherein the at least one flange is releasably fastenable to an adjacent one of the brace members.
 19. A connector for holding two vertically stacked modules of a palletless packaging system in assembled relation, the module of the palletless packaging system being of the type having a pair of opposed end walls and a pair of opposed, substantially parallel brace members extending between the pair of opposed end walls, the connector comprising: (a) a lower channel dimensioned to straddle the top edge of and connect to the end wall; (b) an upper channel extending along some portion of the connector and dimensioned to receive the bottom edge of the end wall of the module thereabove; and (c) an end portion being releasably securable to one of the brace members.
 20. The connector of claim 19 wherein the lower channel of the connector is U-shaped and comprises: (a) a pair of spaced-apart, substantially vertical wall portions; and (b) a horizontal flange interconnecting the pair of vertical walls, wherein the distance between the vertical wall portions approximates the thickness of the end wall being straddled.
 21. The connector of claim 19 wherein the lower channel further includes at least one opening formed in at least one of the vertical walls thereof, wherein the at least one vertical wall is releasably fastenable to the end wall.
 22. The connector of claim 19 wherein the upper channel of the connector is V-shaped and comprises: (a) a pair of spaced-apart walls; and (b) a horizontal flange interconnecting the pair of spaced-apart walls, each of the walls extending upwardly and outwardly from the horizontal flange, wherein the width of the flange approximates the thickness of the end wall received therein.
 23. The connector of claim 22 further including at least one reinforcing rib integrally formed with and extending outwardly from at least one spaced-apart wall of the upper channel.
 24. The connector of claim 19 wherein the end portion of the connector comprises: (a) at least one flange, and (b) at least one aperture formed therethrough the at least one flange, wherein the at least one flange is releasably fastenable to at least one brace member.
 25. The connector of claim 19 wherein: (a) the lower channel is U-shaped and comprises: (i) a pair of spaced-apart, substantially vertical wall portions; (ii) a horizontal flange interconnecting the pair of vertical walls, wherein the distance between the vertical wall portions approximates the thickness of the end wall being straddled; (b) the upper channel comprises: (i) a pair of spaced-apart walls; and (ii) a horizontal flange interconnecting the pair of spaced-apart walls, each of the walls extending upwardly and outwardly from the horizontal flange, wherein the width of the flange approximates the thickness of the end wall received therein. 